User’sGuide

Hondata User Guide © 2003 Hondata

While Hondata believes that our product is safe and useful, and that every effort has been made to ensure the quality of the product, Hondata is not responsible for any damage that may arise from the use of this product. No guarantee is made about the performance of this product. By using this product (including software and any hardware) you agree to abide by these terms.

IMPORTANT - READ CAREFULLY: This Hondata Product License Agreement ("Agreement") is a legal agreement between you (either an individual or a single entity) and Hondata ("HONDATA") for HONDATA'S Product (hardware, software and any associated media (collectively, the "Licensed Product"). By continuing to use the product, you agree to be bound by the terms of this Agreement.

1. COPYRIGHTThe Licensed Product is owned by HONDATA and is protected by New Zealand copyright laws and international treaty provisions. Therefore, you must treat the Licensed Product like any other copyrighted material (e.g., a book or musical recording), except that you may either (i) make one copy of the Licensed Software solely for backup or archival purposes, provided you reproduce and include HONDATA'S copyright and trademark notices contained on the original disk labels on such backup copy, or (ii) transfer the Licensed Software to a single hard disk, provided you keep the original solely for backup or archival purposes. You may not copy any written materials which may accompany the Licensed Product.

2. OTHER RESTRICTIONSYou may not, copy, or modify the Licensed Product, or any backup copy, in whole or in part, or translate such files into any other file format or language, except as expressly provided for in this agreement. You may not rent, lease or sublicence the Licensed Product, but you may transfer the Licensed Product and accompanying written materials on a permanent basis, provided you retain no copies, the recipient agrees to the terms of this License Agreement and immediately contacts HONDATA to inform HONDATA of such transfer. Upon such transfer, your license under this License Agreement is automatically terminated. You may not reverse engineer, de-compile or disassemble the Licensed Product for any purpose whatsoever.

3. TERMYour license is effective upon your acceptance of this agreement and installing the Licensed Product. You may terminate it at any time by destroying the Licensed Product together with all copies. It will also terminate upon conditions set forth elsewhere in this Agreement or if you fail to comply with any term or condition of this Agreement. You agree upon such termination to destroy all copies of the Licensed Product in any form in your possession or under your control.

4. WARRANTYHONDATA OFFERS NO WARRANTY OF PERFORMANCE, EXPRESS OR IMPLIED, WITH REGARD TO THE LICENSED PRODUCT AND ALL ACCOMPANYING MATERIALS. HONDATA FURTHER DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WITH REGARD TO THE LICENSED PRODUCT AND ALL ACCOMPANYING MATERIALS.

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6. DISCLAIMER OF DAMAGESYou assume responsibility for, among other things, (i) the selection of the Licensed Product to achieve your intended results, (ii) the acquisition of other software (including any programming or operating system software) and/or equipment compatible with the Licensed Product, and (iii) the installation, use and results obtained from the Licensed Product. Further, for the express purpose of limiting the liability against HONDATA, you agree that, to the maximum extent permitted by law, HONDATA SHALL IN NO EVENT BE LIABLE FOR ANY DAMAGES WHATSOEVER (INCLUDING WITHOUT LIMITATION, MATERIAL DAMAGES, DAMAGES FOR LOSS OF BUSINESS PROFITS, BUSINESS INTERRUPTION, LOSS OF BUSINESS INFORMATION, OR ANY OTHER PECUNIARY LOSS) ARISING OUT OF THE USE OR INABILITY TO USE THE LICENSED PRODUCT, WHETHER DIRECT, INDIRECT, INCIDENTAL, CONSEQUENTIAL, SPECIAL OR OTHERWISE, REGARDLESS OF THE FORM OF ACTION, EVEN IF HONDATA HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.

7. UPDATESHONDATA may, from time to time, revise or update the product. In so doing, HONDATA incurs no obligation to furnish such revision or updates to you.

8. GENERAL This License is personal between you and HONDATA. It is not transferable and any attempt by you to rent, lease, sublicense, assign or transfer any of the rights, duties or obligations hereunder, except as provided in Section 2, above, is void. This Agreement and the conduct of the parties hereto shall be governed by the laws of the United States of America.

YOU ACKNOWLEDGE THAT YOU HAVE READ THIS AGREEMENT, UNDERSTAND IT AND AGREE TO BE BOUND BY ITS TERMS AND CONDITIONS. YOU FURTHER AGREE THAT IT IS THE COMPLETE AND EXCLUSIVE STATEMENT OF THE AGREEMENT BETWEEN YOU AND HONDATA WHICH SUPERSEDES ANY PROPOSAL OR PRIOR AGREEMENT, ORAL OR WRITTEN, AND ANY OTHER COMMUNICATIONS BETWEEN YOU AND HONDATA OR HONDATA'S AGENT(S) RELATING TO THE PRODUCT.

© 2003 Hondata

Table of Contents

Introduction 4

ECU Installation 5

Shift light installation 6

Clutch switch 8

Setting rev limits 9

Resolving problems 12

ECU problem codes 13

© 2003 Hondata

Introduction

This installation manual covers the installation of all Hondata s200. Some information in this manual will not apply if you are not installing all the Hondata features.

S200 featuresShift lightThis is a high intensity LED wired in parallel with the factory check engine light. At a certain rpm the LED will light as an indication of when you should change gear. The shift light rpm can be set with a dash mounted push button.

VTEC controlThe point where the ECU switches camshafts can be adjusted from 3000-7000 rpm using the dash mounted push button. Unlike other VTEC controllers the ECU will switch ignition and fuel tables at the correctly point to ensure the mixture and ignition is optimum for each camshaft.

Rev limiterThe overall rev limiter can be set up to 9000 rpm using the dash mounted push button.

Boost (optional)Adds tables to the ROM under boost conditions for both fuel and timing on both he low speed cam and the high speed cam.

G-Sensor (optional)The Hondata G Sensor is a module containing a two axis accelerometer which plugs into the s200 Interface Box. It allows you to datalog lateral and longitudinal acceleration simultaneously.

Three stage rev limit (optional)When the car is stationary and the clutch is in, a launch limiter is used so that the revs can be held accurately to maximize traction and repeatability while launching. When the car is moving and the clutch is depressed, a shift limiter reduces engine speed so that full throttle gear changes can be made.

Datalogging/HondaLogger (optional)Windows based real time datalogging system.

ROM Editor (optional)Windows based editing software allows the user to alter fuel and ignition curves, injector sizing, set limits and more. ROM Editor can be used to tune ROMs for use with stage 2, 3 or 4 systems.

© 2003 Hondata

ECU InstallationInstalling the interface boxThe interface box should be located close to the ECU where the wiring will not be pulled or pinched. For datalogging the serial connector should be accessible. It is useful if the interface box is mounted so that the diagnostic LED on the front can be seen if necessary. The interface box does not need to be grounded.

WiringRoute the ECU to interface box cable out either under the lid or through near where the connectors exit the ECU case. In both cases make sure that there is no chance of the cable being pinched or chaffed where it passed out of the ECU. A slot may need to be filed so that there is room of the cable to pass out of the ECU. Make sure the edges are not sharp. A rubber grommet may help.

Connecting the 4 wire leadSimply plug in the connector, this will only plug in one way.

Inserting the ROMsStage 4 ships with a ZIF socket (zero insertion force) and a stack of machine pin sockets high enough to clear the internal air pressure sensor. The sockets and EEPROM should be inserted with the notch pointing towards the wiring harness end of the ECU. This arrangement is only necessary while using the ZIF socket. Once tuning has been completed the ZIF socket should be removed, and an EPROM placed directly into the socket on the ECU.

© 2003 Hondata

Shift Light InstallationInstallation of the shift light

This is a high intensity LED wired in parallel with the factory check engine light. At a certain rpm the LED (and check engine light) will light as an indication of when you should change gear. The shift light rpm can be set with a dash mounted push button. The 470 ohm resistor is built into the shift light wiring and does not need to be added.

Install the LED where the driver can see it (make sure you allow for the steering wheel). The LED is directional so should be mounted facing the driver.

The copper colored wire of the shift light should be wired into ignition switched +12V which is ECU pin A15 (OBD 0) or A25 (OBD I). The shift light can be wired in with the supplied snaplocks or soldered in place (which is recommended). To wire in using the snaplock connector open the snaplock connector and thread the wire from the wiring loom through. Insert the shift light wire, close the connection and squeeze closed with pliers. The snaplock connector can be removed at any time leaving the wire intact.

The silver colored wire of the shift light should be connected to ECU pin B6 (OBD 0) or A13 (OBD I). The engine computer grounds this connection to switch the engine check light on.

Switch on the car. The engine check light and LED should both come on as the ECU primes the fuel pump (for about 2 seconds).

Alternately the shift light can be wired directly across the check engine light in the instrument cluster. The LED is polarized and will not light if wired in reverse, but will not be damaged if this is done accidentally.

© 2003 Hondata

Shift Light InstallationOBD II wiring harness adaptors.

If you have a Hondata system connected to an OBD II Honda, it will have either the 96-98 or the 99-2000 configuration connector. The diagrams below show shift light connections all 96-2000 OBD II vehicles.

© 2003 Hondata

Clutch SwitchPositioning the clutch switch (Stage 3)

For stage 3 a clutch switch needs to be mounted so that it is activated close to the point where the clutch engages. Standard vehicles will have none, one or two clutch switches mounted either above or below the clutch pedal. For some cars the lower position can be used to mount the supplied clutch switch.

The lower position

The easiest location to install the Hondata clutch switch is in the position of the cruise control switch. If cruise control is still used then this will mean that the cruise control will not deactivate when the clutch is depressed, so it is only recommended for use in cars without cruise control.

In this location, the car activates its full throttle shift when the clutch is depressed slightly. As most clutches have some free play in them, screw in the clutch switch until the free play is minimal. Be careful not to remove all the free play as this will cause the clutch toslip and burn out over time.

In this position the switch is sensitive to riding the clutch. If you ride the clutch even the slightly, you car will be rev limited to the full throttle shift point of 6000 rpm.

Custom Switch

The best position for the clutch switch is to use a bracket to locate the clutch switch closed to the pedal pivot point, so that the clutch switch will activate slightly above the clutch disengage point. Alternatively a replacement switch with a longer switching throw can be used (microswitches work well).

Testing the clutch switch

Start the car and bring the revs up to 4000 rpm while stationary. Depress the clutch. The revs should drop to 3000 rpm (or whatever the launch rpm is set to).

If your rev limit is 3000 rpm while you are stationery and 6000 rpm while moving is is likely your clutch switch is stuck on. Unplug your clutch switch and re-test.

Hints

If you do not intend to use launch control immediately then do not plug in the clutch switch. For circuit racing applications add a dash mounted switch in the wiring to the clutch switch so that the clutch switch can be disabled if necessary.

© 2003 Hondata

Setting Rev limitsProgramming the revs

The rpm points are initially set to the following: Launch limiter 3000 rpm (stage 3 & 4) Cam change point 4800 rpm Shift limiter 6000 rpm (stage 3 & 4) Shift light 7800 rpm Rev limiter 8500 rpm Pressing and holding the button for several seconds while switching the ignition on will reset all the rpm points to the Hondata defaults. Do this the first time the system is installed into the car.

Methods of setting revs

There are two methods of setting the rev points: dynamic which is quick and static which is accurate. A video explanation of this is available from http://www.hondata.com/media.html

The launch limiter, cam change point, shift limiter, shift light and overall rev limiter can all be adjusted using the rev set button. Pressing the button will put the computer into a 'setup mode'. If the engine is running, then the revs can be set by varying the engine speed and pressing the brake pedal (dynamic rpm setting). If the engine is not running, the rpm points can be set by pressing the button to set the thousands and hundreds of revs (static rpm setting).

Dynamic rpm setting

Dynamic rpm setting is quick but less accurate than static setting. With your foot off the brake start the engine. Press the rev set button once. The check engine light will start flashing a sequence of between 1 and 4 flashes, which indicates the rpm value that is to be changed. Pressing the button again will cycle through the rpm point that is to be changed 1,2,3,4, 1,2,3,4, 1,2,3,...

Check engine light Function Allowable rpm range

1 flash = launch limiter rpm 1500 - 8000 rpm 2 flashes = cam change rpm 2000 - 8000 rpm3 flashes = shift limiter rpm 5000 - 8000 rpm 4 flashes = shift light rpm 2000 - 9000 rpm

The revs for the launch limiter and cam change point, are set by selecting the mode, bringing the engine revs up to the desired point and tapping the brake pedal. The engine revs at that point will be remembered. Because it is difficult to set the higher rpm points by revving the engine to over 7000 rpm, the shift limiter, shift light are set at twice the revs when the brake pedal is tapped.

© 2003 Hondata

Setting Rev limits1 flash = launch limiter rpm current rpm 2 flashes = cam change rpm current rpm3 flashes = shift limiter rpm twice current rpm 4 flashes = shift light rpm twice current rpm

Examples

To set the launch limiter to 3500 rpm: Press the button once. The check engine light will flash once, with a one second pause between flashes. Increase the engine revs to 3500 rpm and tap the brake pedal. Switch the ignition off. The launch limiter is now set to 3500 rpm.

To set the shift light to 8000 rpm: Press the button four times. The check engine light will flash four times quickly, with a one second pause between groups of flashes. Increase the engine revs to 4000 rpm, and tap the brake pedal. Switch the engine off then restart. The shift light will now be set to 8000 rpm.

Note that if the rev set button is pressed with the brake on, the launch rpm will be set to the engine speed at the time the button was pressed (within the allowable default RPM limits).

Static rpm setting

Static rpm setting is more accurate than dynamic setting but more time consuming to perform. With your foot off the brake turn on the ignition but do not start the car. Press the rev set button once. The check engine light will start flashing the rpm option that is to be changed, as in dynamic setup. Press the button additionally to select the rpm point to change, then tap the brake pedal.

The check engine light will now start flashing the thousands of revs, from 1 to 9 flashes. 1 flash = 1000 rpm, 9 flashes = 9000 rpm. Pressing the button will increase the thousand rev flashes. Tap the brake pedal to select the thousands ofrevs.

The check engine light will then start to flash the hundreds of revs, from 1 to 10 flashes. 1 flash = 0 rpm, 10 flashes = 900 rpm.

Switch the ignition off after setting both static and dynamic the static limits. After the car starts rev limits will not be active for 10 seconds until the Hondata interface board and ECU complete their diagnostics.

© 2003 Hondata

Setting Rev limitsExamples

To set the launch limiter to 3500: Press the button once. The check engine light will flash once, with a one second pause between flashes. Tap the brake pedal. The check engine light will start to flash the thousands of revs. Press the button twice, so the check engine light flashes groups of three (3000 rpm). Tap the brake pedal. The check engine light will start to flash hundreds of revs. Press the button five times, so the check engine light flashes groups of six (500 rpm). Tap the brake pedal. Switch the engine off then restart. The launch limit is set to 3500 rpm.

To set the shift light to 8000 rpm: Press the button four times. The check engine light will flash four times quickly, with a one second pause between groups of flashes. Tap the brake pedal. The check engine light will start to flash the thousands of revs. Press the button eight times, so the check engine light flashes groups of eight (8000 rpm). Tap the brake pedal. The check engine light will start to flash hundreds of revs. Tap the brake pedal without pressing the button. The shift light is set to 8000 rpm.

Rev counter accuracy

The static method used to determine the engine speed is very accurate, usually much more accurate than the rev counter which can be between 5 and 10 % out. The rev limits that you set will often be different from that shown on the rev counter.

© 2003 Hondata

Resolving ProblemsTake note of what the LED on the front panel of the interface box does when the ignition is switched on (with early interface boxes this LED is inside the interface box).

The engine will only rev to 3200 rpm

In this situation the error codes cannot be retrieved from the ECU (the check light will remain on solidly). The ECU is in ‘limp home mode’, which means that there is a problem accessing the ROM so the ECU is running off a backup processor. The ECU will use fixed ignition and fuel values. Possible causes for this problem:

• ROM inserted the wrong way around.• Incorrect ROM for the ECU (see page 6).• Jumper J1 not installed or incorrect value.• Bad solder connection to the socket or latch IC (especially with surface mount latch ICs).

The interface box LED does not come on

The interface box is not getting power from the ECU. Possible causes for this problem:

• Interface box cable is not plugged in correctly.• The cable has broken wires or is shorting out. Check for +5V between CN2 or CN3 pins 1 and 3 on the ECU.

The interface box LED flashes once and goes out

Reset the interface box by holding down the rev set button while switching the ignition on.

The interface box LED is flashing slowly

The problem lies with the Hondata interface box not being able to communicate with the ECU. Possible causes for this problem:

• Incorrect ROM used for the ECU.• ROM inserted the wrong way around.

The interface box LED flashes and stays on

This is normal behaviour for the interface box. The problem lies with the ECU or car. Short the diagnostic connector and read the error codes (see appendix 2 for instructions on how to do this.)

© 2003 Hondata

ECU Problem Codes

What are ECU problem codes?ECU problems codes are diagnostic outputs from the ECU, used to indicate in what area a problem lies. Usually the check engine warning light (on the dash) will come on for a serious problem, but will not necessarily come on for a minor problem. The ECU will remember problem codes with the ignition off; the only way to clear the codes is to disconnect the battery or remove the hazard fuse for half a minute or so.

How to read ECU codes

Pre OBDI ECUsTo read the codes, turn the ignition on and look at the LED inside the ECU. The LED is visible through a small plastic window in the top of the ECU. The ECU can signal simultaneous problems by blinking separate codes, one after the other. Problem codes 1 - 9 are indicated by 1 - 9 flashes, problem codes over 9 use one long flash as ten short flashes.

OBDI and later ECUsFind the diagnostic connector, which is a two wire blue connector found near the passengers feet, or in the center console.Short out the diagnostic connector with a piece of wire. The check engine light on the dash will flash the problem codes.

Problem codes

1 O2A - Oxygen sensor #12 O2B - Oxygen sensor #23 MAP - manifold absolute pressure sensor4 CKP - crank position sensor5 MAP - manifold absolute pressure sensor6 ECT - water temperature sensor7 TPS - throttle position sensor8 TDC - top dead centre sensor9 CYP - cylinder sensor10 IAT - intake air temperature sensor

© 2003 Hondata

ECU Problem Codes12 EGR - exhaust gas re-circulation lift valve13 BARO - atmospheric pressure sensor14 IAC (EACV) - idle air control valve15 Ignition output signal16 Fuel injectors17 VSS - speed sensor19 Automatic transmission lockup control valve20 Electrical load detector21 VTEC spool solenoid valve22 VTEC pressure valve23 Knock sensor30 Automatic transmission A signal31 Automatic transmission B signal41 Primary oxygen sensor heater43 Fuel supply system45 Fuel system too rich or lean48 LAF - lean air fuel sensor54 CKF - crank fluctuation sensor58 TDC sensor #261 Primary oxygen sensor63 Secondary oxygen sensor65 Secondary oxygen sensor heater

OBD II specific codes

67 Catalyst system efficiency below threshold70 Automatic transmission malfunction71 Cylinder 1 misfire or a random misfire72 Cylinder 2 misfire or a random misfire73 Cylinder 3 misfire or a random misfire74 Cylinder 4 misfire or a random misfire75 Cylinder 5 misfire or a random misfire76 Cylinder 6 misfire or a random misfire80 Exhaust gas re-circulation86 ECT (engine coolant temperature) sensor90 Evaporative emission control system91 Fuel tank pressure sensor92 Evaporative emission control system (insufficient purge flow)

© 2003 Hondata